Metal Cutting Theory & Practice

ME 352: Manufacturing Technology - II

01 of 10

Back rake angle

Variations in the back rake angle affect the direction of chip flow. As the back rake angle increases (within limits) with other conditions remaining constant, tool life will increase slightly & cutting force required will decrease. Generally, small rake angles are used for machining hard materials, while steeper rake angles are used for more ductile materials. Exceptions to this rule include tools for brass, bronze, certain plastics and non-metals. Back rake angles may vary from 00 to 350 for various applications.
ME 352: Manufacturing Technology - II
02 of 10

Effect of Tool Geometry

Side rake angle

Variations in this angle affect the direction of chip flow. This angle enables the tool to cut more freely.

Effect of Tool Geometry

Side rake angles vary from 00 to 220 or more for different applications.
ME 352: Manufacturing Technology - II
03 of 10

End relief angle

Relief angles are also known as clearance angles.
Effect of Tool Geometry

The purpose of end relief angle is to prevent the end of the tool from rubbing on the work. If an end relief angle is too small, it will wear down, rubbing with w/p will start, the tool and the work can get too hot, and chatter marks or a smeared surface may show up on the work. An excessive relief angle reduces the strength of the tool. Relief angles are usually fairly small, from 30 to 100
ME 352: Manufacturing Technology - II
04 of 10

Side relief angle

The purpose of side relief angle is to prevent the side which is at the cutting edge, from rubbing on the work.

Effect of Tool Geometry

The side relief angle allows the tool cutting edge to penetrate into the metal (w/p) & promotes free cutting by preventing the side flank of the tool from rubbing against the work.
ME 352: Manufacturing Technology - II
05 of 10

End cutting edge angle

The purpose of this angle is to avoid rubbing between the edge of the tool and the workpiece. Excessive end cutting angle reduces tool strength. It may vary from 70 to 300

Effect of Tool Geometry

ME 352: Manufacturing Technology - II

06 of 10

Side cutting edge angle

This is formed by the straight (side) cutting edge and the side of the tool shank.

Effect of Tool Geometry

Increasing side cutting edge angle tends to widen the thin chip and influences the direction and chip flow.
Angle may vary from 00 at 300 for machining various materials.
ME 352: Manufacturing Technology - II
07 of 10

Nose radius
The nose radius is the dimension of the round which forms the nose of the tool bit.
Effect of Tool Geometry

For rough turning, a small nose-radius usually about 0.4mm (1/64) is used.

For finish turning, a radius from 0.4-1.6mm (1/64 to 1/16) is used, depending upon the size of the tool. A turning tool with a nose radius of 0.8mm (1/32) will produce a satisfactory finish for general rough or finish turning. Tool large a nose radius results in chatter.
ME 352: Manufacturing Technology - II
08 of 10

Effect of Nose radius on Surface Finish

=
Ra roughness, mean value R tool-nose radius f feed (feed rate) mm/min or mm/rev

Effect of Tool Geometry

ME 352: Manufacturing Technology - II

09 of 10

Feed Marks in Turning

Feed marks: spiral profile on the machine surface
Effect of Tool Geometry

ME 352: Manufacturing Technology - II

10 of 10